TECHNICAL SPECIFICATIONS
PRODUCTION QUAID DRILL
FQ12095MC Mariana Coefield
PAGE SPECIFICATION NUMBER REVISION EFFECTIVE DATE Page 2 of 39 SPN – 0003 4 10/27/2011
Washington Metropolitan Area Transit Authority 600 5th Street, NW Washington, DC 20001
SPECIFICATIONS PACKAGE PRODUCTION QUAD DRILL
REV. DATE REVISION DETAILS RELEASE NO. INIT. 0 02/22/2011 Draft RLN-000 MRB 1 03/25/2011 Edited format RLN-000 AB 2 04/08/2011 Revised content RLN-000 AB 3 04/29/2011 Reviewed RLN-000 MRB 4 10/27/2011 Revised content RLN-000 MJT/DKH
EDITED BY: Michael J. Thomas DATE: October 27, 2011 Michael J. Thomas – Acting Superintendent, TRST
APPROVED BY: Darvin L. Kelly DATE: November 14, 2011 Darvin L. Kelly - General Superintendent, TRST
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Table of Contents
1.0 SCOPE...... 5
1.1 GENERAL REQUIREMENTS ...... 5 2.0 APPLICABLE DOCUMENTS ...... 6 3.0 TECHNICAL SPECIFICATIONS ...... 6
3.2 MATERIAL ...... 7 3.3 BRAKES ...... 8 3.4 WHEELS, AXLES, BEARINGS, FRAME, AND SUSPENSION ...... 8 3.5 INSULATION ...... 9 3.6 ENGINE ...... 10 3.7 FUEL TANK ...... 10 3.8 PROPULSION SYSTEM REQUIREMENTS ...... 11 3.9 EXHAUST SYSTEM...... 11 3.10 PNEUMATIC SYSTEM ...... 12 3.11 HYDRAULIC SYSTEM ...... 12 3.12 ELECTRICAL SYSTEMS ...... 14 3.13 CABIN ...... 15 3.14 RADIO ...... 17 3.15 EXTERIOR LIGHTS ...... 18 3.16 TRAVEL SPEED ...... 18 3.17 CLEARANCE ...... 18 3.18 INITIAL PREPARATION AND SERVICING ...... 19 3.19 PAINT ...... 19 3.20 NOISE EXPOSURE ...... 20 3.21 SHIPPING ...... 21 3.22 OPERATORS MANUAL ...... 21 3.23 PARTS AND INSTRUCTION MANUALS ...... 21 3.24 REPAIR PARTS AND SERVICE ...... 22 4.0 INSPECTION AND ACCEPTANCE TESTING ...... 23 5.0 SAFETY CERTIFICATION (N/A) ...... 23 6.0 WARRANTY ...... 23 7.0 TRAINING ...... 23
7.2 TRAINING DELIVERABLES ...... 25
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8.0 DELIVERY OF INSTRUCTION ...... 27
8.2 DELIVERY AND COMMISSIONING ...... 29 8.3 EQUIPMENT START-UP...... 30 9.0 APPENDICES ...... 31
9.1 STANDARD CLEARANCE PACKAGE ...... 31 9.2 COST ESTIMATE DETAILS ...... ERROR! BOOKMARK NOT DEFINED.
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1.0 Scope
1.1 GENERAL REQUIREMENTS
1.1.1 The Offeror compliance response shall be clause by clause (for Section 3) and inserted into the RFP or on a standalone document.
1.1.2 Design, manufacture, delivery, testing and commissioning of Production Quad Drill. The Production Quad Drill shall contain a climate controlled, fully enclosed cab for two (2) operators, two hydraulic work heads, one over each rail, with four (4) drills per head. It shall be capable of drilling eight (8) holes in ties simultaneously or four (4) holes on one side only. The heads will be adjustable to accommodate pattern changes in tie plates and have keyless chucks. The Production Quad Drill shall be designed to work in third rail territory.
1.1.3 Equipment shall be delivered with a full complement of all parts necessary to ensure successful start-up and total operational capability for a minimum of one (1) year which includes three (3) PMI cycles.
1.1.4 Training of WMATA’s staff in the operation and maintenance of the Production Quad Drill and supply of training programs. Refer to section 7.0.
1.1.5 Supply of full supporting documentation for training, as well as for the operation and maintenance of the Production Quad Drill.
1.1.6 Supply of specialized and general tools, test equipment for diagnosis, maintenance and repair of the Production Quad Drill, if applicable. Supply of the tools and equipment shall be as agreed between WMATA and the Contractor.
1.1.7 The Production Quad Drill shall be put into service by a factory trained representative. The Contractor shall have after sales service support with available factory trained service technicians to assist in start-up and training.
1.1.8 The Contractor shall provide a list of optional equipment that is not identified within this Specification but which the Contractor feels would be beneficial for WMATA to have in order to operate or maintain the Production Quad Drill. The unit price for each optional piece of equipment shall be provided along with the Offeror’s proposal.
1.1.9 The Production Quad Drill shall comply and conform to all Federal, State, and Local environmental, safety and health regulations in force, at the time of delivery. SPN-0003 PRODUCTION QUAD DRILL Rev. 4 - 10/27/2011 Page 5 of 39
1.1.10 Upon completion of manufacture and before any operation shall begin, all parts shall be clean and free from scale, rust, water, and/or any contamination. All materials and workmanship must be of good quality for the intended use. 2.0 Applicable Documents a) ASTM-A325: Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength. USS/SAE grade 5 or 8 for assembly hardware.
b) American Association of Railroads (AAR), Wheel and Axles Manual, 11th Edition
c) MIL-HDBOOK-1472, Human Engineering Design
d) WMATA’s Safety and Security Certification Plan e) Federal Transit Administration’s Handbook for Transit Safety and Security Certification, FTA MA-90-5006-02-01, Final Report, November 2002. 3.0 Technical Specifications 3.1.1 GENERAL
3.1.2 SCOPE: This specification covers the technical aspects for a Production Quad Drill (hereunder referred to as the “Unit”) to be utilized as a work unit to support the tie gang and other wayside related maintenance.
3.1.3 DESCRIPTION: The Unit shall contain a climate controlled fully enclosed cab for two (2) operators, two hydraulic work heads, one over each rail, with four (4) drills per head. It shall be capable of drilling eight (8) holes in ties simultaneously or four (4) holes on one side only. The heads will be adjustable to accommodate pattern changes in tie plates and have keyless chucks, a stand-alone diesel powered engine, and controls for the propulsion and braking systems. Both ends of the unit shall be equipped with tow pad eyes (refer to 3.4.9). The unit shall be equipped with an integral, hydraulically operated, rail to rail turntable that will allow clearance of the third rail when turning unit, remain level during this process, and shall have a positive lock for travel mode. Turntable shall have a warning light and buzzer.
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3.1.4 REQUIREMENTS: The Unit shall be capable of travelling up a 6 % grade. Minimum speed when traveling up a 6 % grade shall be 5 MPH under dry or wet conditions. The Unit shall maintain a minimum speed of 20 MPH when traveling on grades of 3 %. Equipment must be capable of negotiating all WMATA track, tunnels, and structures, and stay within the dynamic envelope. Equipment must conform to all WMATA restrictions regarding height, width, and weight. Unit shall also be designed to work in third rail territory. Specifications and drawings are provided in Section 9 of this contract detailing height, width, and weight.
3.1.5 BRAND NAME or EQUAL: The Unit shall be a Nordco Quad Drill or equal. It shall be of the latest type in production at the time of delivery. Production parts and components shall not be obsolete, nor near the end of their planned production life. All components shall be readily available for a minimum of three (3) years from date of delivery.
3.1.6 RELIABILITY: The Unit design, construction, and materials used shall ensure that it will function reliably and efficiently in sustained operations under harsh and extreme conditions in adverse railway environments.
3.1.7 WORKMANSHIP: The Unit shall be free from defects such as incomplete welds, welds that cross welds, corrosion, loose or improper fasteners, any leaks or contamination, and any other defects that would impair or limit the operation or serviceability. All welds must comply with the associated and established American Welding Society (AWS) standards.
3.1.8 MAINTENANCE: The Unit shall incorporate a design which allows ease of access, service, replacement, and adjustment by maintenance and operational personnel including filters, fluids, and other components. Contractor shall supply one set of special tools if required for service or repairs, along with diagnostic equipment necessary to evaluate the overall functionality of the complete operating system of the vehicle to include all OEM engine and transmission systems.
3.1.9 REMOTE DRAIN PORTS: All fluid reservoirs shall have remote drain valves/ports located on outboard frame rails and terminated with a JIC cap.
3.2 MATERIAL
3.2.1 All steel plates, shapes, bars, and sheets shall be of a quality that has good weldability, high impact resistance and meets IZOD impact toughness at low temperatures (00 to 400 Fahrenheit). Steel items shall be of alloys and grades normally used for maintenance of way equipment and railway rolling stock.
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3.2.2 Design of structural members subject to normal working loads shall have a minimum design safety factor of 2 to 1. Structural members shall be designed to withstand impact stresses with a minimum safety factor of 3 to 1. It is generally recognized that this is only a minimum recommended guideline and greater design safety factors may be required as necessary.
3.2.3 All fasteners shall meet requirements of ASTM-A-325 for structural components and grade USS/SAE 5 or 8 for assembly hardware as a minimum. Manufacturer or Contractor shall use certified fasteners. Manufacturer or Contractor shall be aware of the high possibility of counterfeit fasteners available. All fasteners shall be plated or anodized to avoid corrosion or galvanic reaction to the mating surfaces.
3.2.4 All bolt applications shall have at least two (2) full threads protruding beyond the nut after the fastener has been torqued and no more than six (6) threads protruding beyond the nut.
3.2.5 Torque seal shall be used to indicate hardware movement on wheel studs and where applicable.
3.2.6 All fastener certifications shall be maintained by the builder for inspection by WMATA until all warranty/reliability periods have expired.
3.2.7 All non-ferrous metals shall be of alloys having strength and corrosion resistance suitable for the service and operating environment intended.
3.3 BRAKES
3.3.1 The Unit shall have a failsafe spring-applied parking brake on all wheels. The parking brake shall be capable of holding the Unit on a 6 % grade.
3.3.2 Brake shoes shall be of a composition type.
3.4 WHEELS, AXLES, BEARINGS, FRAME, AND SUSPENSION
3.4.1 Wheel gauge to fit standard track gauge of 56-1/2 inches.
a) Diagonal Measurement:
1) + or - 1/8” Maximum Tolerance for Wheel Bases up to 9 ft.
2) + or - 3/16” Maximum Tolerance for Wheel Bases Greater Than 9 ft.
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3.4.2 Wheel diameter shall be minimum sixteen (16) inch, hub mounted cast steel. Wheel profile and axle assembly dimensional drawings, including back to back, shall be supplied to the COTR for approval prior to assembly.
3.4.3 No excessive vibration, wobble, or eccentric action shall occur at any speed for which the unit is intended. Suspension shall provide for damage-free operation under maximum foreseeable operating stresses. The entire machine shall withstand a free drop of 6" to a nonresilient surface without impairing normal travel or operating functions. Derail guards shall be incorporated near each wheel to cover inboard and outboard rail area, so that in the event of derailment, the machine shall not leave the rail. The derail guards shall be designed so as to prohibit any part of the Unit to touch the contact rail at any time. (Reference track work drawings for dimensions.)
3.4.4 The Unit shall be equipped with two (2) axles.
3.4.5 The axles shall be three (3) inch minimum diameter and suitably sprung to achieve safe travel at maximum operating conditions of FRA Class 3 track profile.
3.4.6 All axle bearings shall be solid pillow block and designed for 250,000 mile service life.
3.4.7 The Unit wheel-to-wheel impedance of each wheel axle assembly shall be less than 0.2 ohms when measured with a 100 volt source over the frequency range of 1 to 10 kilohertz.
3.4.8 The Unit shall be provided with a means of lifting it with a crane hook without damage to any equipment. Lifting points and balance points must be clearly marked and labeled. The Unit shall come equipped with a spreader bar and all rigging required designed for loading and unloading the equipment on a flat bed truck and shall be stowed on the equipment in an accessible area on the Unit.
3.4.9 One (1) Tow Eye of 2 1/8" in diameter shall be provided at each-end of the Unit. The Tow Eye shall be 14", + or ½”, from the top of rail to centerline of tow eye as measured with new wheels. Refer to Section 9.1.6.
3.4.10 One (1) Tow Bar with 2" pins of a strength equal to 150% of the Draw Bar force required by the maximum load coupled to the Unit of six (6) foot length or longer if required, and shall be provided and stowed on an accessible area of the Unit. Refer to Section 9.1.6.
3.5 INSULATION
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3.5.1 The Unit axles shall not be insulated. The Unit shall not be converted from an insulated design by bonding around insulating parts. If a shunt bond is used, its design must be approved by WMATA. The Unit shall give a positive indication of track occupancy under any condition of loading.
3.6 ENGINE
3.6.1 The engine shall be diesel, with adequate horsepower to accomplish equipment tasks. Engine emissions shall be in compliance with EPA standards for minimum Tier III emissions levels.
3.6.2 The engine shall have the following features:
a) A dry type, two-stage air cleaner with centrifugal pre-cleaner,
b) A restriction indicator for the air cleaner,
c) A spin on primary and secondary fuel filter, and
d) A remote spin-on oil filter and a remote engine oil drain shall be provided.
3.6.3 The engine shall be equipped with an engine shut down with audible alarm for low oil, low coolant, and/or high temperature conditions.
3.6.4 The engine shall be equipped with engine compartment side panels and insulated against weather, sound, and vibration.
3.6.5 The engine exhaust pipe shall discharge to one side using a bent 90-degree elbow, and as close to the overall height of the Unit as possible. The muffler shall be mounted as close to the engine as possible.
3.6.6 Engine model number and engine type shall be provided with the proposal submission.
3.7 FUEL TANK
3.7.1 Capacity of fuel tank shall provide for continuous operation of the machine for a period of no-less-than 24 hours of operation at 50% of the rated output.
3.7.2 Filler opening shall have a minimum diameter of 1-1/2", a removable strainer (accomplished only with the use of common hand tools), and a hinged or chained vented filler cap.
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3.7.3 The filler opening shall be located so as to make it impossible for a fuel can or nozzle to contact electrically energized parts. Tanks shall be located to eliminate fire hazard from spill, overflow, or drain of fuel.
3.7.4 The tank shall be located on the Unit, in a position that will provide protection against rupture due to collision or derailment.
3.7.5 The tank shall incorporate a top loading port, a sight gauge for fuel levels, a remote fuel gauge (cab-console); and a 3/4" drain valve with a pipe plug and provisions for a padlock.
3.7.6 The tank shall comply with MFPA FCLCH 30 (Flammable and Combustible Liquids Code Handbook).
3.8 PROPULSION SYSTEM REQUIREMENTS
3.8.1 The Unit engine shall provide power for propulsion and hydraulic functions. A hydrostatic, pressure compensated drive pump and motor configuration coupled to drive sprockets shall be used for propulsion. The unit shall be four wheel drive.
3.8.2 For towing purposes, a mechanism approved by WMATA shall be provided to permit easy disengagement of the drive system to preclude damage to any component. Large step-by-step metal etched placards of instruction shall be installed inside the cab as well as on the outside of the Unit for towing operations.
3.8.3 Automatic back up alarm. FRA 214 D compliant timeable change of direction alarm. Defeatable in forward work mode.
3.9 EXHAUST SYSTEM
3.9.1 The exhaust system shall be so located that it will cause no adverse temperature rise in any other part of the equipment and so that a minimum of heat and exhaust gas can reach the operator.
3.9.2 Machines equipped with enclosed cab or cab top shall have the exhaust discharge at least 12" above the top or as Tunnel Restrictions apply. (See Tunnel Clearance Drawings.)
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3.9.3 Stainless steel tubing shall be used for all exhaust piping. Not more than 36" of flexible metal exhaust pipe may be used, where necessary to reduce transmission or vibration. All exhaust piping shall be properly braced to eliminate shocks at all junctions, and at the interfaces between the manifold and muffler. Vibration dampeners may be used if necessary. The system shall provide for expansion, contraction, vibration, and stress produced by operation of the machine. The system shall comply with the requirement for Diesel Engines Exhaust and Emission Test. (See SAE-y-24A, SAE-j-1003, and SAE-j-1243) as well as EPA Recommendations Regarding Air Pollution.
3.9.4 When utilizing exhaust tubing in the vertical position, the end shall be bent or a rain cap incorporated to eliminate moisture entry into the exhaust system.
3.10 PNEUMATIC SYSTEM N/A
3.11 HYDRAULIC SYSTEM
3.11.1 The hydraulic system shall conform to the recommendation of the National Fluid Power Association (NFPA), American National Standards Institute (ANSI), and the International Standards Organization (ISO).
3.11.2 Upon completion of manufacture and before any operation, all parts of the system shall be cleaned and free from contaminants. Threads, holes, cuts, flares and machining must be deburred and cleaned.
3.11.3 Manufacturers must pre-filter all oil through a ten (10) micron or finer filtering system.
3.11.4 All reservoirs shall be designed and constructed to prevent entry of foreign matter, including water, and sized to protect the hydraulic system against excessive heat or thermal conditions. Reservoir shall be of 60-gallons size or larger.
1) Baffles to separate intake and return lines to facilitate the separation of air and foreign matter from the hydraulic fluid, separate pump inlet from the settling portion of the tank, and shall direct flow toward tank walls for maximum heat dissipation.
2) Access panels large enough for complete cleaning, inspection, maintenance, and servicing of filters with an accessible means to empty the reservoir in the event the fluid is to be retained.
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3) An air inlet breather which is of sufficient capacity to maintain approximately atmospheric pressure at maximum demands on the hydraulic system and to assure vacuum at pump inlet(s) shall not exceed 60% of pump Manufacturers recommendations. Air breather system shall be equipped with a 10 micron or finer filter, either cartridge or spin-on type.
4) A thermostatically controlled oil cooler shall be utilized. A thermometer, in plain view, protected from damage, shall be mounted as near the intake line as possible.
5) Hydraulic system shall contain a failsafe circuit to interrupt hydraulic flow in the event of catastrophic failure, i.e. hose rupture. System shall include an audio visual alarm at operator station followed by a time delayed engine shut down. An override switch shall be incorporated. Location of tank low oil safety probe/sensor (four (4) inches below low mark in sight glass) shall not be affected by work or travel in super elevated curves of up to 6 inches.
3.11.5 Fluid temperature in the reservoirs shall not exceed 180° F at the reservoir outlet(s) while operating in a 100° F ambient. The minimum fluid temperature after 5 minutes, warm up to or operation shall be at least 60° with a 20° F ambient.
3.11.6 Where failure of the power plant or pump can immobilize components, in a position which would prevent moving of the Unit, a battery operated emergency pump shall be provided in the circuit to allow normalization of all equipment components and release failsafe brakes for movement of the Unit to a proper location.
3.11.7 All hydraulic hoses shall be secured by stud and clamp method. Hose protective covers shall be used throughout where applicable to prevent scuff and chaffing. Nylon ties or zip strips shall not be acceptable. Hoses and fittings shall not be painted.
3.11.8 All safety locks shall be painted in “red” color and be controlled from the operator console.
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3.12 ELECTRICAL SYSTEMS
3.12.1 Electrical Systems shall conform to the regulations of the American National Standards Institution (ANSI) and the International Standards Organization (ISO) where applicable.
3.12.2 Upon completion of manufacture and before any operation shall begin, all parts shall be clean and free from scale, rust, water, and/or any contamination. All materials and workmanship must be of good quality for the intended use.
3.12.3 Sequence of operation and electrical, physical, and schematic drawings showing the exact circuit(s) in use on the machine and large enough to be easily followed during trouble-shooting shall be furnished. Subsequent changes shall be covered by new drawings furnished to the customer.
3.12.4 Whenever practical, components shall be interchangeable.
3.12.5 All cables and wiring shall be protected and enclosed in conduit, tubing and wire trays and routed to prevent exposure to damage. Adhesive type materials shall not be used to protect cable or wiring.
3.12.6 DC Systems, when grounded shall have negative ground.
3.12.7 Battery charging alternators shall have a rated capacity to handle all equipment and accessories with a 50% reserve.
3.12.8 The DC Electrical System shall be 24 volts and have a PLC control system.
3.12.9 Circuit breakers shall be utilized for overload protection as required. All wiring with potential differences of 50 volts or more shall be separated by a clearance of 12 inches.
3.12.10 The battery box shall be constructed of non magnetic corrosion resistant stainless steel material and shall incorporate adequate drain holes and provide proper ventilation when lead acid batteries are used. The batteries shall be provided with a disconnect switch and shall have a cover.
3.12.11 Cabinets shall be of steel construction. Clearance between walls and bare "live" parts shall not be less than 1-1/2", unless affected interior surfaces utilize insulative plastic or fiber sheeting, where a potential in excess of 50 volts exists. Cabinets shall be weatherproof.
3.12.12 Panels shall be readily removable and parts easily accessible.
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3.12.13 Adequate lighting shall be provided in cabinets.
3.12.14 Pipes other than electrical conduit shall not enter cabinets.
3.12.15 Nominal voltages used shall be plainly shown on outside of cabinet.
3.12.16 All parts and groups of parts shall be identified by function and clear, simple, exact reference to service diagram and parts list. Integral units such as a circuit board, shall be considered as one part, if intended to be replaced as a unit. Complete parts identification shall be shown where practical, in order to minimize errors and time consuming reference to drawings or lists.
3.12.17 Wires shall be equipped with good quality ring lug, push-on or pin and screw type terminals and identified with permanent numbered markers, color coded when practical, terminal posts shall be plainly marked. Once used, a number or color code shall not be reused for a different circuit. All wires shall be neatly dressed and clamped.
3.12.18 Housing containing heat producing elements shall be properly ventilated.
3.12.19 The Electrical System shall provide a New Mar 32-12-15 DC-DC Converter or WMATA approved equivalent to power the 12 VDC Radio Communication System.
3.13 CABIN
3.13.1 The Operator Cab shall provide seating space for two (2) operators. The glazing material shall be 1/4" laminated safety glass. The windshield wiper(s) shall clear 75 % of the front and rear glazing, and shall maintain full blade contact with the glazing while the Unit is traveling at maximum speed.
3.13.2 The cab door shall be equipped with lock hasps which incorporate a 5/8" minimum I.D. Hasp Ring, and to be in addition to any other type door locks.
3.13.3 The Cabin shall be Heated, Air-conditioned (Visionaire Inc. or WMATA approved equivalent) and Ventilated. Fresh air intakes shall assure a minimum of three (3) changes of air volume per hour. Interior temperatures shall be thermostatically controlled through operator adjustment, such that at maximum heating conditions, a temperature of 85° F can be sustained and at maximum cooling conditions, a temperature of 68° F can be sustained.
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3.13.4 Operator seats shall be constructed of durable non-toxic materials. The operator seat position shall be equipped with a cushioned seat and back, employing natural or man-made leather, over 3" low smoke foam cushion (Chestnut Ridge 200) or WMATA approved equal. The operator’s seat shall have a seat belt. The operator seat position shall be adjustable to accommodate operators ranging in height from 5'2" to 6'4".
3.13.5 The seat shall be placed in the cab to allow an unrestricted view of the front and rear of machine. If there is a restricted view, mirrors and a color high definition camera system approved by WMATA will be installed on the machine.
3.13.6 All switches, valves, levers, controls, and adjustments used to start, stop, or operate the machine shall be clearly labeled with weather and wear resistant plates permanently affixed to the machine or component. Controls used in continuous operation of the machine shall be within easy reach of the operator and shall not interfere with his/her view of the work. Instruments and gauges not inside a closed, lockable cab, shall be protected from vandalism.
3.13.7 The engine shall not start with controls in travel position.
3.13.8 A red emergency shutdown control shall be quickly accessible to the operator.
3.13.9 The shut down control shall stop the engine and apply Unit brakes. a) SWITCHES (minimum): 1) Windshield Wiper - Front 2) Windshield Wiper - Rear 3) Defroster Fan - Front 4) Defroster Fan - Rear 5) Headlights - Front/Rear 6) Interior Lights - On/Off 7) Exterior Work Lights - Front/Rear b) GAUGES (minimum) shall be the back lighted type: 1) Oil Pressure Engine 2) Water Temperature 3) Volts 4) Fuel Level 5) Tachometer – RPM
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6) Speedometer c) CONTROLS (minimum): 1) Throttle 2) Brakes 3) Forward / Reverse 4) Gear Select 5) Railroad Horn (overhead pull cable) 6) Low decibel Electric Horn (mushroom button on operators console) 7) Parking Brake 8) Engine Kill- Mushroom Button
3.13.10 Cab shall include a five (5) LB dry type fire extinguisher and a kit.
3.14 RADIO 3.14.1 Provisions shall be made within the cabin for mounting, by the Contractor, a transit vehicle radio with separate speaker and separate microphone and an exterior antenna. The Contractor shall furnish a source of 12 VDC power as described in Section 3.12.19, through a circuit breaker rated at 3 AMPS for the control circuit and 40 AMPS for the transmitter:
1) Description) Astro XTL 5000 Digital Mobile Radio;
2) Mobile Astro XTL 5000 W5 482-512 MHZ 20-40 Watts 128 Channel (120W);
3) ENH: Software Astro Digital Common Air Interface Operation (G806);
4) ENH: Software Smartnet System (G50);
5) ENH: Digital ID Display (G114);
6) ALT: Remote Mount W4, W5, or W7 with 17 foot Cable (W496);
7) Antenna with cables;
8) Programming: Talk group template, etc;
9) Installation within vehicle.
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3.15 EXTERIOR LIGHTS
3.15.1 Each end of the Unit shall be equipped with the following Exterior Lights: Two (2) - 4" LED Red Lens Marker Lights
Two (2) – Headlights. U.S. Reflector Xeon X-4500 Broad Beam
Suitable – Worklights. U.S. Reflector Xeon X-4500 Wide Flood
The operation of these lights shall be as follows, and automatically switchable as the vehicle direction is selected:
CAB-END LEADING FORWARD REVERSE
RED Marker Lights OFF ON
Head Lights ON OFF
REAR-END LEADING: (The Inverse of Cab-End Leading)
Amber Strobe light. Federal Signal Model 651 Strobe/Beacon or WMATA approved equivalent.
3.16 TRAVEL SPEED
The Unit shall be driven and permit operation at maximum torque speed, in both directions of travel. The power plant shall permit operation under full design load at speeds of not less than 20 mph, on level tangent track conditions.
3.17 CLEARANCE
3.17.1 Clearance of fixed system points: The Unit and appurtenances shall successfully operate and negotiate within the constraints of the physical structures of the Rapid Transit System. The following drawings exhibit the guide way constraints: ° Crane Car Design Loading
° Track work (Tunnel Profiles)
° Track work (Station Profiles)
° Track work (Track bed)
NOTE: All applicable drawings are attached for reference in the Exhibits Section
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3.17.2 Components which may encroach upon track, signal, crossing, or other structures on, or along a railway shall have a positive mechanical lock to secure these components in a safe position for travel.
3.17.3 No Component shall be less than 3" above the plane extending from the ball of one (1) rail to the ball of the other rail with fully compressed suspension and fully cut multi wear wheels where applicable. Clearance to the cover board shall be maintained within the above constraints.
3.17.4 All components which may present a hazard to operator, assistant or bystanders shall be protected with a shield or safety device.
3.17.5 Handrails or grab irons shall be installed wherever it is intended that personnel board the Unit. The lowest step used for boarding the machine shall not be more than 12" above the top of the running rail. Any area more than 3 ft. above the top of the running rail (where persons are expected to walk or pass) shall be protected by rigid tubular handrails. The handrails shall be no less than 1-1/4" O.D. diameter, 42" high, with a secondary rail 24" high. A 3" kick board shall be provided to prevent entry into potentially hazardous areas.
3.18 INITIAL PREPARATION AND SERVICING
The machine shall be delivered completely lubricated and serviced with all equipment installed for immediate operation, except for fuel. Water cooled engines are to be protected from freeze up by a 50/50 solution of ethylene glycol base anti-freeze (rust inhibitive type) unless otherwise specified, and the radiator marked or tagged to show the Manufacturer and type of coolant used and actual protection afforded.
3.19 PAINT
3.19.1 Manufacturer shall use paints which meet OSHA regulations and standards, and do not have any known history of biological hazards due to long term exposure. Passive respirators and eye protection shall be the only safety or health equipment necessary to protect WMATA workers making future repairs.
3.19.2 Manufacturer shall also utilize proper surface preparation, including the use of rust inhibiting primer compatible to the surface finish. The surface coat shall be epoxy, urethane, or other hi-tech type compatible with the primer coat, and have a glossy, high quality, durable finish which resists dulling, fading, or chalking when maintained with suitable cleaning compounds.
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3.19.3 Exposed parts of the machine shall be painted U-Tech (Chrome Yellow), # UTCB9355- MX/GL, Urethane (or WMATA approved equivalent) except as follows:
Diesel Fuel Tank ...... GREEN
Hydraulic Reservoir ...... BLUE
Coolant Tank ...... GRAY
Wheels and Handrails ...... BLACK
Lifting Lugs...... BLACK
Safety Locks ...... RED
Jacking Points or Pads ...... BLACK
Engine and Other Parts ...... Manufacturer’s Option
3.19.4 The name of fluid and the words "CHECK DAILY" shall be stenciled on each tank in 1" letters. Total machine weight with all tanks filled shall be plainly marked on both sides of the machine in 1-1/2" letters: WEIGHT ______Lbs. (Manufacturer/Contractor to fill in the blank.) The machine shall be numbered PQD01 in eight inch black stenciled letters and numbers. PQD01 shall also be stenciled inside the cab in plain view of the operator. Stand Clear, Danger, High Temp, Pinch Point and all other applicable safety warning labels/stencils shall be utilized where needed.
3.19.5 All equipment shall be protected by finishes suitable to the environment. Moving parts shall be self-lubricated or shall contain provisions for full application of all lubricants.
3.19.6 Exteriors exposed to the elements shall be finished by a minimum three (3) coat process. The base coat shall contain a rust inhibitor phosphatized coating and be thoroughly bonded to base metals.
3.20 NOISE EXPOSURE Shall not exceed permissible exposure for operators, assistants, and workmen for a continuous eight-hour work day. Noise sources and machine cab shall be treated to bring about total compliance of the following conditions.
Less than 90 dBA at 7 ft. from the power plant housing and less than 85 dBA at 50ft. from the centerline of the track, or comply with MIL-HDBOOK-1472, Human Engineering Design. SPN-0003 PRODUCTION QUAD DRILL Rev. 4 - 10/27/2011 Page 20 of 39
3.21 SHIPPING Equipment shall be constructed, prepared, and loaded so that it will withstand without damage handling likely to be encountered during delivery. Valuable and easily pilfered parts such as batteries, tools, and loose small items shall be shipped in such a manner as to resist pilferage.
3.22 OPERATORS MANUAL
3.22.1 One complete set of operator instruction manual shall accompany the machine in a waterproof container permanently affixed in the cab of the machine. Additional sets of manuals shall be forwarded as follows: Twelve (12) additional sets shall be forwarded to:
WMATA
Attention: James Barrett
5700 Capitol Gateway Drive
Suitland, Maryland 20746
3.22.2 Manuals shall contain complete and easily read diagrams of all systems on the machine and shall employ American Standard symbols and notations.
3.22.3 Machine shall incorporate, in operator's cab, where possible, a metal etched pictorial placard designating lubrication point, indicating types of lubricant, location on machine and frequency of checking or changing lubricants. These placards must be designed by part number for the appropriate machines. 3.22.4 Machine shall incorporate one set of Operators Manuals packaged in a waterproof container permanently affixed in the operators cab.
3.23 PARTS AND INSTRUCTION MANUALS
3.23.1 One complete set of parts, maintenance and overhaul procedure manuals shall accompany the machine upon delivery. Manuals will be for all major components including engine, drive train, and all sub systems to include electrical and hydraulics. Electrical components and hydraulic valves shall be tagged with a number system that will correspond with all drawings and parts list.
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Twelve (12) additional complete sets of manuals shall be submitted in hard copy and twelve (12) on writable CD’s in Microsoft Word format upon delivery of the machines to:
WMATA Attention: James Barrett 5700 Capitol Gateway Drive Suitland, Maryland 20746
NOTE: Manuals SHALL contain OEM part numbers and supplier.
3.23.2 Manuals shall contain complete and easily read diagrams of all system on the machine and shall employ American Standard symbols and notations. Complex technical data package including drawings, part numbers, and sources for all spare parts shall be provided.
3.23.3 Machine shall incorporate, in operator's cab, a metal etched pictorial placard designating lubrication point, indicating types of lubricant, location on machine, and frequency of checking or changing lubricants. These placards must be designed by part number for the appropriate machines. Parts book must also contain the comprehensive lubrication chart for the appropriate type machines.
3.24 REPAIR PARTS AND SERVICE
3.24.1 Equipment shall be delivered with a full complement of all parts necessary to ensure successful start-up and total operational capability for a minimum of one (1) year which includes 3 PMI cycles.
3.24.2 Additionally, the Manufacturer shall provide a comprehensive list of spare components inclusive of current prices. A separate list of parts necessary for routine maintenance and recommended on-hand quantities shall also be submitted. The list will be based on industry standard reliability failure predictions, and availability Mean Time Between Failures (MTBF) reliability data.
3.24.3 Reliability and availability of this equipment is critical. The successful offeror is required to provide short-notice on-site support when required, and to quickly provide unique parts, assemblies, and subassemblies throughout the equipment warranty period.
3.24.4 The OEM part number will be retained on all commercially available standard parts and components purchased by the offeror from external sources. OEM parts modified by the offeror to meet the needs of this procurement will be clearly identified by a unique number in the parts manual.
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4.0 Inspection and Acceptance Testing
4.1.1 Upon equipment delivery, the Contractor shall perform acceptance testing at WMATA. Acceptance test plans shall be submitted by the Contractor ten (10) working days prior to performing the test and approved by WMATA, prior to testing. As a minimum acceptance tests shall include:
1) Braking Capability Verification
2) Air-Compressor Capacity Verification
3) Hydraulic System Performance Check
4) System Clearance Checks (within the WMATA System)
5) Alternator Capacity Verification
6) Work Components Operation Verification
7) Radio Frequency & Power Test
8) Vehicle Lighting Test
9) Heating & Cooling Test 10) Noise Level Measurements
4.1.2 Delivery shall take place 180 days after award at the Branch Ave. location.
4.1.3 A Manufacturer's Representative shall place equipment in service and instruct the Authority operators, mechanics, and supervisors at a location, to be specified by the Authority (not necessarily at the machine delivery point). 5.0 Safety Certification (N/A) 6.0 Warranty 6.1.1 The Contractor shall offer a one (1) year warranty on all manufactured components of the Unit. Pre-Manufactured items installed on the Unit will be covered by the OEM manufacturers’ warranties unless the warranty is less than one year. 6.1.2 Reliability and availability of this equipment is critical. The successful Contractor is required to provide short-notice on-site support when required, and to quickly provide unique parts, assemblies, and subassemblies throughout the equipment life cycle. 6.1.3 The Contractor shall comply with the warranty provisions, as stated in the Special Provisions, of this Contract document. 7.0 Training
7.1.1 The Contractor shall provide the service of one (1) person for a period of two (2) weeks to SPN-0003 PRODUCTION QUAD DRILL Rev. 4 - 10/27/2011 Page 23 of 39
provide start-up assistance in the operation of the Unit.
7.1.2 The Contractor shall provide a maintenance training course for thirty five (35) WMATA equipment maintainers and twenty (20) equipment operators. This course shall be given at WMATA and shall be of duration not less than twenty (20) consecutive calendar days of instruction and shall not be concurrent with the stand-up assistance and training.
7.1.3 All training, as described below, shall take place by the vendor prior to acceptance of equipment or materials by WMATA. Operations and maintenance training may take place as a combined class by agreement of the Department of Operations. The number of OPER employees to be trained will be specified on a contract-by-contract basis. However, the minimum number shall be 20 for operation training and 35 for maintenance training. Those persons shall be identified by WMATA.
7.1.4 Operations training will be tailored specifically to WMATA equipment, and designed to teach the day to day operation of all equipment. The training will be sufficient to bring personnel to a level of operating proficiency such that routine vendor support is not needed.
7.1.5 Maintenance training will be tailored specifically to WMATA equipment, and be designed to develop the knowledge and skills required to maintain all item(s) delivered under the contract. Maintenance training will be subdivided into two major levels. They are
a) System Level Maintenance Training, covering:
1) Theory of operation of the system and its major components.
2) System configuration
3) Preventative maintenance, consisting of written procedures and schedules for the periodic maintenance of all equipment.
4) Written and validated inspection procedures and a system - level troubleshooting guide (to the lowest field - replaceable unit).
b) Shop Level Maintenance Training, covering:
1) Detailed theory of operation (and principles of the engine, hydraulic, electrical, and mechanical) to module, board, and /or device level.
2) Component level troubleshooting and component replacement.
3) Testing and alignment (installations) procedures of repaired units.
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7.2 TRAINING DELIVERABLES OPER TRNG requires the following non-copyrighted course materials to be delivered by the vendor, according to the following specifications.
1) Training Plan containing the data necessary to begin scheduling instruction. The plan must be submitted to TRNG ten days after NTP. The plan must address for approval a proposed time line that ensures that all deliverables are approved and training is presented before the equipment is placed into service.
a. List of courses and their duration.
b. Recommended class size.
c. Student qualifications/Prerequisites. For the purpose of course development and presentation, vendors should assume all WMATA students are high school graduates (or equivalent), and that maintenance personnel will possess the ability to use basic hand tools and electronic test equipment.
d. Instructor qualifications. A description of instructor qualifications, a resume, curriculum vitae, or other description of instructional qualifications must be submitted to TRNG as part of the Training Plan. The description should document a thorough knowledge of the subject equipment, an understanding of the adult learning process, and demonstrated experience in vocational instruction.
2) Instructor’s Guide, to contain all the information and direction necessary for the instructor to make an effective presentation. It shall include adequate guidelines to conduct a comprehensive training program. Individual lessons within the course will be organized as separate blocks (or modules) which may be taught as a unit. In some instances, the same standard operating procedures could be used for train operators, transportation supervisors, and central control supervisors. The Instructor Guide should contain, at a minimum:
a. Program Overview
(1). A statement of overall program goals
(2). Lesson plans (a session by session outline containing the following):
A- Student learning objectives, stated in measurable terms
B- Overview of each lesson SPN-0003 PRODUCTION QUAD DRILL Rev. 4 - 10/27/2011 Page 25 of 39
C- Suggested instructional methods/learning activities
D- Required equipment and /or resources E- Required time for each topic, lesson and course.
b. Evaluation device(s) (written and/or practical tests) designed to measure the extent to which students have met the learning objectives, with an answer key for each of the tests developed. Tests should use a multiple choice format, and have been validated in a pilot course or by some other means agreed to by OPER. Whenever possible, a practical hands-on test shall be developed to demonstrate the transference of operational/mechanical skills.
3) Student Manual, to include all materials for the student to interact in the learning situation. It shall contain, at a minimum:
A- Program overview/introduction
B- Statement of overall program goals
C- Learning objectives, stated in measurable terms that specifically describe desired behaviors or knowledge to be gained.
D- Prose treatment (not outline format) fully developed content presentation, developed in the same modular format as the Instructor’s Guide.
E- Illustrations, charts, graphics, and duplication of each visual aid used during course presentation in order to enhance content presentation and provide a course reference. F- Problems/questions related to lesson content, as appropriate.
4) Audio-visual aids (handouts, transparencies, slides, films, and computer presentations). Visual aids are required for each circuit or wiring diagram and all activities not demonstrable in the classroom.
5) Supplemental materials. A functional mockup, or a functional representation, is required of any equipment which requires theoretical discussion. This may be in the form of an animated schematic, a model of the equipment, an actual device, an interactive video training device, or a TRNG - approved substitute. All mock-ups become the property of WMATA.
A- Number of Copies, The contractor shall deliver final copies to WMATA as follows: One complete set of training materials will be in a specified electronic format or
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camera ready copy.
Five copies of all student and instructor materials, to be used for archival purpose in the TIES Technical Document Center (TDC).
A set of complete student materials for each participant enrolled in training classes.
8.0 DELIVERY OF INSTRUCTION
8.1.1 All instruction will be presented in accordance with approved training materials as specified under deliverables.
8.1.2 All training will be coordinated through TIES TRNG.
8.1.3 Courses will be attended and monitored by TIES TRNG. Unsatisfactory performance may result in the suspension of the training until such time as the specified discrepancies are corrected.
8.1.4 When multiple presentations of the same class are scheduled, there will be a minimum of a five-day period between the first presentation and the remainder of the presentations to facilitate possible corrections.
8.1.5 No courses will be permitted to start without approved training materials on-hand in sufficient quantities to conduct instruction.
8.1.6 Penalties for non-compliance will be in accordance with the penalty provisions of the contract or purchase.
8.1.7 TRAINING MANUALS AND DOCUMENTATION
8.1.8 The Contractor shall provide twelve (12) sets of Operation and Maintenance Manuals and three (3) complete sets of full size blue prints.
8.1.9 Manuals for 8-1/2" x 11" pages shall be 10" to 11-1/2" wide (depending on rug size) and 11" to 12" high. The binders shall not exceed 3" overall thickness. Punched holes shall be on 3/4" centers. Folding pages will be permitted (11" x 17", "Z” folded) where the information to be conveyed cannot be presented clearly on single pages. Manuals for 8- 1/2" x 11" pages may be divided into Book 1, Book 2, etc., if the required material cannot be accommodated within the maximum binder thickness. Table of Contents shall be provided in each book.
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8.1.10 All sections shall be sub-divided, to the extent required by the subject matter, into the following topics:
A- General Sub-systems Description and Operation.
B- Block Diagram.
C- Signal Floor Diagrams.
D- Functional Schematics.
E- Functional Wiring or piping Diagrams.
F- Troubleshooting Techniques
G- Lubrication and Cleaning, including frequency, Methods and Trade Identifications of Recommended Materials; Component Locating and Description
H- Inspection and Maintenance Standards, Including Wear Limits. Settings and Tolerances.
I- Installation and Removal.
J- Test and Evaluation Procedures.
K- Recommended Overhaul.
8.1.11 All parts shall be identified and cataloged within each individual system.
8.1.12 OEM reliability data and documentation for manufacturers recommended scheduled maintenance requirements for all major components, assemblies and subassemblies will be provided as an integral part of the technical manuals. Engine manuals MUST include troubleshooting guide as well as service/overhaul manual.
8.1.13 Technical manual wiring diagrams related to on-board diagnostics and automated components shall identify critical test points and corresponding electrical values.
8.1.14 Technical manual diagrams shall identify critical test points with corresponding pressures/temperatures/values.
8.1.15 Technical manuals shall contain fault tree and problem / cause style troubleshooting guides for electrical and hydraulic systems.
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8.2 DELIVERY AND COMMISSIONING
8.2.1 Equipment shall be constructed, prepared, and loaded so that it will withstand, without damage, handling likely to be encountered during delivery. Valuable and easily pilfered parts such as batteries, tools, and loose small items shall be shipped in such a manner as to resist pilferage.
8.2.2 Delivery of the equipment to WMATA’s Alexandria Rail Yard shall take place 180 days after Notice to Proceed (NTP), at the following address:
WMATA 3101 Eisenhower Avenue Alexandria, VA 22314
8.2.3 Contractor shall be responsible for FOB destination and offloading the Unit onto the track designated by WMATA.
8.2.4 Complete parts and instruction books shall be delivered according to the address below as outlined by the following:
a) 180 days after NTP - two sets of preliminary manuals will be delivered for review.
WMATA Attention: James Barrett Branch Ave Rail Yard 5700 Gateway Drive Suitland, Maryland 20746
8.2.5 Acceptance test plans shall be submitted by the Contractor ten (10) working days prior to performing the test and approved by WMATA, prior to testing.
8.2.6 Upon delivery of the Unit, the Contractor may inspect and correct any damage that may have occurred during shipment on the Owner’s property.
8.2.7 The Contractor may be permitted to carry out specific commissioning work on the Owner’s property.
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8.3 EQUIPMENT START-UP
8.3.1 The Unit will be put into service by a factory trained representative. The Contractor shall have after sales service support with available factory trained service technicians to assist in start-up and training.
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9.0 Appendices
9.1 STANDARD CLEARANCE PACKAGE
9.1.1 Crane Car Design Loading
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9.1.2 Rapid Transit Vehicle Design Loading
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9.1.3 Design Vehicle Dynamic Outline Diagram – Tangent Track
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9.1.4 WMATA Rapid Transit Car Clearance Envelope
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9.1.5 METRO Rapid Transit Car – Dynamic Outline, Under Floor Car Clearance
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9.1.6 Tow Bar
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COMPLIANCE WITH TECHNICAL SPECIFICATIONS
Production Quad Drill
OFFEROR:______
DATE: ______
Comply Comments/Questions Section Title Y/C/N
1.0 SCOPE
2.0 APPLICABLE DOCUMENTS
3.0 TECHNICAL SPECIFICATIONS
GENERAL
3.1
3.2 MATERIALS
3.3 BRAKES
3.5 INSULATION
3.6 ENGINE
3.7 FUEL TANK
3.8 PROPULSION SYSTEM REQUIREMENTS
3.9 EXHAUST SYSTEM
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3.10 PNEUMATIC SYSTEM N/A
3.11 HYDRAULIC SYSTEM
3.12 ELECTRIAL SYSTEM
3.13 CABIN
3.14 RADIO
3.15 EXTERIOR LIGHTS
3.16 TRAVEL SPEED
3.17 CLEARANCE
3.18 INITIAL PREPARATION AND SERVICING
3.19 PAINT
3.20 NOISE EXPOSURE
3.21 SHIPPING
3.22 OPERATORS MANUAL
3.23 PARTS AND INSTRUCTION MANUALS
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3.24 REPAIR PARTS AND SERVICE
4.0 INSPECTION AND ACCEPTANCE TESTING
6.0 WARRANTY
7.0 TRAINING
7.2 TRAINING DELIVERABLES
8.0 DELIVERY OF INSTRUCTIONS
8.2 DELIVERY AND COMMISSIONING
8.3 EQUIPMENT START-UP
9.0 APPENDICES
Notes:
Y – Yes Complies with Requirements
C – Needs further clarification …provide comments and issues requiring additional information.
N – Does comply …provide details of requirements not complied
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